Method and device for producing components or profiles

ABSTRACT

A method for producing components or profiles from at least one solidifiable plastic mass in an injection moulding facility, said method comprising stationary mould components and mould components which are movable with respect thereto. The method includes injection of solidifiable plastic mass into a runner formed in the movable mould components and, from there, via connections either in portions into one or more mould cavities. The runner is enclosed by at least one stationary, temperature-controlled mould component. A continuous runner mass strand is formed with attachment mass strands, which is transported away from the casting site with increasing cooling and solidification and increasing length, together with the filled mould cavities and mould cavity portions. The runner mass strand, together with the connection mass strands, after its solidification and after opening the mould cavity or the mould cavities is separated from the component(s), and the component or the components is/are ejected.

The invention relates to a method for producing components or profilesfrom at least one solidifiable plastic mass in an injection mouldingfacility, said method comprising stationary mould components and mouldcomponents which are movable with respect thereto, wherein the movablemould components contain at least one mould cavity and the stationarymould components have at least one casting site, via which thesolidifiable plastic mass is injected into the area between thestationary mould components and the mould cavity/ies in the movablemould components, while moving the movable mould components with themould cavity/ies away from the casting site. The invention furtherrelates to a device for producing components or profiles from at leastone solidifiable plastic mass in an injection moulding facility, saiddevice comprising stationary mould components and mould components whichare movable with respect thereto containing at least one mould cavity,wherein the stationary mould components have a heatable leading part anda coolable trailing part and have at least one casting site in theregion of the leading part and/or the trailing part.

Such a method and such a device are known from EP 2 205 420 B1, forexample. This method, known as EXJECTION®, is used to produce elongateprofiles or strips from a solidifiable plastic mass in a mould having alower and an upper mould part while injecting the plastic mass into acavity in a profiled mould insert which is located on a linearly movablecarriage. In this case, the injected plastic mass is transported, withprogression and continuous extension of the profile formed or the stripformed and with progressive solidification of the plastic mass, bymoving the slide away from the casting site out of the mould. Theplastic mass is injected until the profile or the bar has reached itsintended length. The profiled mould insert, together with the uppermould parts or mould inserts comprising the casting insert, forms closedcavity portions only at the beginning and at the end of the injectionprocess. During the movement of the profiled mould insert, the plasticmass, after filling the first end portion of the mould cavity, remainspositioned with a free front portion relative to the upper mould part,wherein the mould cavity is further filled in the mould insert. Thisknown method thus involves a combination of an injection mouldingprocess and an extrusion process for producing elongate plastic finishedparts, in particular made of thermoplastic materials. Since thecomponent is formed directly from upper stationary mould inserts duringthe linear movement of the carriage, the production of a qualitativelysatisfactory surface in this area requires a particularly careful anddelicate coordination of the parameters of the injection process.However, these surface areas differ optically from the surface of thecomponent formed in the cavity.

From DE 10 2015 003 206 A1, a method and a device for producing tapesfrom thermoplastics and continuous fibres by means of the EXJECTION®technology are known. A nozzle is provided therein, with which twoinjection units are associated, wherein pourable polymer material isconveyed by two injection units alternately to the nozzle and from thenozzle to transported fibres through an impregnating device. In thiscase, a matrix is formed from the pourable polymer material into whichthe fibres are embedded.

From WO 2016/097012 A1 a method and a device for producing an electricalline with a line core and with an outer casing surrounding it are known.In a continuous shaping method, individual casing portions of the outercasing are successively formed by surrounding the line core with asolidifiable plastic mass by means of a tool mould. The outer casing isformed in at least one partial portion with a cross-sectional geometrywhich is variable in the longitudinal direction.

EP 2 746 026 A2 addresses a method and a device for producing plasticpreforms from a thermoplastic material, wherein the molten thermoplasticmaterial is introduced continuously under pressure into a hot runner ofa hot runner mould. A transport device having multiple cavities andhaving a surface which has openings of the cavities is guided over asurface of the hot runner mould, wherein at least one opening of acavity is always positioned above the hot runner.

EP 2 712 721 A1 addresses a method for producing hollow bodies, inparticular catheters, wherein this method is likewise based on theEXJECTION® technology.

The object of the invention is to further develop and further improvedthe method and device of the above-mentioned type, in particular to beable to produce thick-walled components and components with complexgeometry—both elongate profiles and items in larger numbers—to ahigh-quality and with a uniform surface quality in an economic,cost-effective manner. The method and the device should also allow for alarge degree of freedom with respect to the design of the componentgeometries.

The object is achieved according to the invention by a method having thefollowing steps:

-   a) injection of solidifiable plastic mass into a runner formed in    the movable mould components and, from there, via connections-   b₁) either in portions into an individual mould cavity-   b₂) or one after the other into individual mould cavities,-   c) wherein the runner in the region of the casting site, as well as    in a leading zone located on the one side of the casting site in a    direction counter to that of the movement of the moving mould    components and in a trailing zone located on the other side of the    casting site in the direction of movement of the moving mould    components, is enclosed by at least one stationary,    temperature-controlled mould component,-   d) wherein in the runner, a continuous runner mass strand is formed    with attachment mass strands, which is transported away from the    casting site with increasing cooling and solidification and    increasing length, together with the filled mould cavities and mould    cavity portions,-   e) wherein the runner mass strand, together with the connection mass    strands, after its solidification and after opening the mould cavity    or the mould cavities, is separated from the component(s), and-   f) the component or the components is/are ejected.

The device according to the invention is characterised in that themovable mould components either contain an elongate mould cavity orindividual cavities arranged in a row and have a runner designed as arecess, which is connected via connections either to the elongate mouldcavity or to the individual cavities, wherein the runner is enclosed bythe leading part and the trailing part in the closed mould in the regionof the leading part and the trailing part.

By means of injecting the plasticised mass into a runner, the inventionopens up the possibility of filling both individual cavities and cavityportions of elongate cavities via the connections. As a result, evencomponents with complex geometry can be formed with high quality. Thecavities, which are confined to the local attachment points of theconnections, enable components to be manufactured with a uniform,flawless surface. The method according to the invention therefore hasthe advantages of the EXJECTION® technology known from the prior artwithout being associated with its disadvantages.

In a preferred embodiment of the invention, the method is adiscontinuous method in which the movable mould components are movedlinearly. A discontinuous method allows the production of components offinite length or of individual components limited in number by thenumber of individual mould cavities.

An alternative embodiment of the method according to the invention as acontinuous method, in which movable mould components are continuouslyjoined together, are filled, the component(s) is/are removed from themould, and the mould components are recycled for refilling at thecasting site, is particularly advantageous. A continuous method, inwhich the movable mould components are moved along a closed circle, isparticularly preferred. These variants facilitate the production of an“endless” profile or the production of a large number of individualcomponents, wherein this number is not limited by the number of mouldcavities. A continuous manufacturing method is terminated when theprofile has reached the desired length or when the desired number ofindividual components has been achieved.

In order to keep the injected solidifiable plastic mass in the plasticstate in the region in which filling of the mould cavity/ies isprimarily carried out via the connections in the runner, it isadvantageous if the mould component surrounding the leading zone orforming the leading zone is heated as a moulding mass in the case ofthermoplastics, or is cooled as a moulding mass in the case ofthermosetting plastics or elastomers.

In the trailing zone, immediately on the other side of the casting site,it is advantageous in the case of thermoplastics for the plastic mass tobe cooled as a moulding mass in the runner, the connections and themould cavity/ies, to support the solidification process, and in the caseof thermosetting plastics or elastomers initially to be heated as amoulding mass to achieve a chemical crosslinking of the mass. The mouldcomponent surrounding the runner in the trailing zone is thereforeeither cooled or heated.

In the preferred embodiment of the discontinuous method, thesolidifiable plastic mass fills an elongate mould cavity in portions orindividual mould cavities running in a row via the connections, whichare formed in at least one mould insert, which is arranged on a linearlymovable carriage.

In the discontinuous method, after filling the mould cavity or all mouldcavities, the movable mould components are stopped, the supply ofplastic material is stopped and steps e) and f) of claim 1 follow.

In the continuous method according to the invention, it is particularlyadvantageous if the solidifiable plastic mass partially fills a circularcircumferential mould cavity in portions or individual mould cavitiessuccessively arranged in a circle via the connections, wherein the mouldcavity or the individual mould cavities is or are provided within mouldinserts which follow the circular outer circumference of a rotary unitfollowing the circular shape directly following one another.

The continuous method according to the invention facilitates aparticularly significant productivity increase. In this context, it isparticularly advantageous that in step e) the solidified runner massstrand and the solidified connection mass strands are continuouslyseparated after the emergence of the mould inserts from the trailingzone by means of successively opening of the mould inserts. It isfurther particularly advantageous that, following step e), the mouldinserts are successively opened completely, either the component formedin the respective cavity is ejected or the component continuously formedin the mould cavity extending in a circle is partially removed from themould, wherein the mould inserts are then closed in sequence and, duringthe continuous rotation of the rotary unit, successively enter theleading zone again.

In a preferred embodiment of a device according to the invention, whichallows the production of components according to the discontinuousmethod, the device has a linearly movable carriage as a movable mouldcomponent which is provided with at least one mould insert containingthe elongate mould cavity or the individual mould cavities, over theextension of which the runner is formed as a straight recess in themould insert.

The elongate mould cavity in the mould insert may be straight for theproduction of straight profiles; however, it may also be overall curvedarcuately and thus allow the production of slightly arcuately curvedcomponents.

In a preferred embodiment of a device according to the invention, whichfacilitates a continuous production of components, the device has arotary unit with a circular outer circumference as a movable mouldcomponent, on which the mould inserts immediately following the circularshape are arranged, which respectively contain either a mould cavity ortogether contain an individual mould cavity following a circular shape,wherein the runner extends as a circular circumferential recess over allmould inserts.

Both in the variant with a carriage and in that with a rotary unit, theleading part and the trailing part have free edge portions facing themould insert or the mould inserts with edge surfaces which, when themould is closed, tightly cover the runner. Thus, in those areas of themould in which the solidifiable plastic mass is injected, it is ensuredthat the cavity or cavities are filled with solidifiable plastic massvia the runner and the connections and that the trailing part eithercools or heats the solidifiable plastic mass in the runner as well as inthe connections and in the cavity/ies, depending on whether the mass isa thermoplastic or an elastomer or thermosetting plastic.

In a further advantageous embodiment of the invention, the leading partis offset or placed lower relative to the trailing part so that therunner gap in the region below the leading part is thinner walled thanin the region below the trailing part. The pressure of the injected masscan thereby be maintained longer in the already filled portions of themould cavity.

In a further preferred embodiment of the invention, the device has anembossing device with embossing stamps, which can be inserted locally inthe runner in the region of the connections. The embossing stampstherefore provide pressure on the mass in the connections, specificallyfor an increase in the pressure in the cavity after filling. In thisway, particularly thick-walled regions of the cavity can be optimallyfilled with solidifiable plastic mass.

In a further variant of the invention, the embossing device hasembossing stamps which can be inserted into the cavity or the cavities.This measure makes it possible to locally strengthen the solidifiableplastic mass during cooling, in particular in those areas in whichvoluminous elements of the component are formed, so that the volumeshrinkage is correspondingly reduced.

Actuation of the embossing device by means an embossing strip which isarranged on a stationary mould component is particularly advantageous,wherein the embossing stamps are positioned in a movable mould componentin such a way that, during the movement of this mould component, theycan be successively brought into their embossing position.

In a further advantageous embodiment of the device according to theinvention, a flow brake device with a stationary actuating striparranged on a stationary mould component, and with sliders mounted in amovable mould component, which are moved in the region of the leadingpart successively from the runner as soon as a portion of the runner haspassed the nozzle in the direction of the trailing part, is provided. Asa result, the mass in the cavity is better supplied with pressure afterthe respective portion of the runner has passed under the nozzle.

In particular, in a device according to the invention with a rotaryunit, i.e. when performing the continuous method, it is advantageous iftwo injection units are used to ensure a constant supply of the runnerand the cavities with solidifiable mass. A correspondingly designeddevice therefore has two injection units and a channel block with twonozzles which can be supplied with solidifiable plastic mass by theinjection units, wherein a channel extends from each nozzle into thecentre of the respective channel block. Here, in one embodiment of theinvention, one of the two channels can now be alternately connected, viaa change-over valve, to a further channel, which runs to the castingsite in the region of the leading and trailing parts. In an alternativeembodiment, in the centre of the channel block via needle valve nozzles,the two channels can be connected simultaneously or alternately withanother channel, which extends to the casting site in the region of theleading and trailing parts. Above all, this embodiment variant makes itpossible to ensure a constant pressure of the solidifiable plastic massvia a corresponding actuation of the needle valve nozzles when changingthe injection units.

Another advantageous embodiment of the invention facilitates theproduction of components from two different solidifiable plastic massesin a two-component method. In this device, two nozzles are provided,which are both positioned in the leading part or are a component of aunit of the injection moulding machine, wherein each nozzle can besupplied with a correspondingly composed separate solidifiable plasticmass.

Further features, advantages, and details of the invention will now bedescribed in greater detail with reference to the drawing, whichschematically depicts multiple exemplary embodiments.

In the figures:

FIGS. 1a to 1c show views of an embodiment of a device according to theinvention in different stages of the method,

FIG. 1d shows a cross-sectional view in the region of a nozzle,

FIG. 2 shows a second embodiment of the device according to theinvention in a representation analogous to FIG. 1 c,

FIG. 3 shows a third embodiment of the device according to the inventionin a representation analogous to FIG. 1 c,

FIGS. 4a to 4c show a fourth embodiment in representations analogous toFIGS. 1a to 1 c,

FIGS. 5, 5 a and 5 b show views of a embodiment variant of an embossingdevice,

FIGS. 6, 6 a and 6 b show views of another embodiment of an embossingdevice,

FIG. 7 show a view of another embodiment variant of a device accordingto the invention in a cross-sectional view,

FIG. 7a shows a sectional view along the line VIIa-VIIa of FIG. 7,

FIGS. 8, 9, 10 and 11 show views of embodiments with two injection unitsin sectional views,

FIG. 12 shows a view of a further embodiment variant of a deviceaccording to the invention with two nozzles in a representationanalogous to FIG. 1 c,

FIG. 13 shows a view of a further embodiment variant of a deviceaccording to the invention in a representation analogous to FIG. 11, and

FIGS. 13a to 13c show views of an embodiment variant of a flow brakedevice.

In all figures of an injection moulding machine, only those componentsare shown that are directly or indirectly involved in the moulding ofthe components to be produced. Location designations in the followingdescription, such as above, below, left, right, and the like, refer tothe illustrations in the figures.

The embodiment variants of the invention shown in FIGS. 1a to 1 c, 2, 3,4 a to 4 c, 12 and 13 are embodiment variants for producing one or morecomponents in a discontinuous method. In these embodiment variants ofthe invention, two mould parts are provided, which can move towards andaway from one another for opening and closing. Not shown in this manner,an attached mould insert 1 includes one upper mould part, through whicha nozzle 2 having a nozzle hole 2 a leading away from the injection unit5 (merely indicated in the Figures) extends, through which plasticisedmass exits under pressure during operation of the injection mouldingmachine. In the mould insert 1, a leading part 3 forming a leading zoneand a trailing part 4 forming a trailing zone are inserted, wherein inthe variants shown in the figures, the nozzle 2 is positioned betweenthe leading part 3 and the trailing part. Both the leading part 3 andthe trailing part 4 are in particular made of several parts and providedin a known manner with channels for passing a tempering medium. Heatingelements 13 for obtaining the injected mass in the melted state are alsofound in the leading part 3 if a thermoplastic mass is involved. In analternative embodiment of the invention, the nozzle extends through theleading part, and the trailing part closes directly after the nozzle.

On the second lower mould part, an elongate carriage 6 is arranged to belinearly displaceable in the direction of the arrow P1 in the figuresand in the direction of its longitudinal extension. A mould insert 7 ispositioned in the longitudinal extension of the carriage 6, which in theembodiments shown in FIGS. 1a to 1 c, 3, 4 a to 4 c and 12, contains asingle, elongate mould cavity 8, and in the embodiment shown in FIG. 2,contains a plurality of mould cavities 8′ successively arranged in arow. The mould cavity 8 is designed, for example, such that an elongatecomponent, for example a strip or a profile, is produced therein. Themould cavities 8′ are intended, for example, to produce a large numberof identical individual parts. The mould cavity 8 is connected, inparticular regular intervals, via connections 9, to a runner 10 on thetop of the mould insert 7, and each mould cavity 8′ is in particularconnected to a runner 10 with a connection 9—a distribution channel. Therunner 10 is a recess extending substantially over the longitudinalextension of the mould cavity 8 or over the extension of the row ofmould cavities 8′ in the mould insert 7. In the embodiments shown,between the connections 9, the runner 10 has narrowed or shallowportions 10 a, and recessed portions 10 b at the mouth regions of theconnections 9. In all portions 10 a, 10 b, the runner 10 preferably hasa constant width over its longitudinal extension, which is adapted tothe flowability of the solidifiable plastic mass and the respectivegeometry of the mould cavity 8 or the mould cavities 8′, and measures afew millimetres. In the embodiment shown, the nozzle hole 2 a of thenozzle 2, has a diameter which is smaller than the width of the runner10.

As the sectional view in FIG. 1d shows, the mould insert 7 has multiple,for example two, jaws 7 a, which enclose the mould cavity 8 where thereare multiple cavities 8′, the connections 9 and the runner 10, arebraced against each other, and can be moved away from one another toopen the cavity 8 and cavities 8′. In the embodiment shown, above therunner 10, the jaws 7 a form a V-shaped recess in cross-section intowhich, in the closed position of the mould, lower edge portions 3 a, 4 aof the leading part 3 and the trailing part 4 engage, the edge portionsdesigned mirror-inverted in cross-section, therefore preferablyV-shaped, and extending linearly in the longitudinal direction of thecarriage. Narrow edge surfaces 3 b, 4 b on the edge portions 3 a, 4 a ofthe leading part 3 and the trailing part 4 close the runner 10 fromabove in those areas where the leading part 3 and the trailing part 4are respectively located during the injection process of thesolidifiable plastic mass and the linear movement of the carriage 6.

By means of a number of ejectors 12, the manufactured component or themanufactured components are removed from the mould with the jaws 7 aopen. In one embodiment with a number of mould cavities 8′, at least oneejector 12 is provided per mould cavity 8′.

For linear movement of the carriage 6 in the direction of the arrow P1,at least one drive, not shown, in particular a linear drive, isprovided, which is operated in a known manner, for example electrically,mechanically, pneumatically, or hydraulically.

FIG. 3 shows an embodiment in which a component is produced, which isoverall slightly arcuately curved. By means of a correspondingconfiguration of the jaws, an overall curved cavity 8 with connections 9corresponding to varying lengths is provided in the mould insert 7.Otherwise, this embodiment corresponds to that according to FIGS. 1a to1 c.

The embodiment shown in FIGS. 4a to 4c largely corresponds to that ofFIGS. 1a to 1 c, but has a special feature compared to the leading part3 offset or positioned lower relative to the trailing part 4, so thatthe runner gap in the region below the leading part 3 is thinner walledthan in the region below the trailing part. 4 The pressure of theinjected mass can thereby be maintained longer in the already filledportions of the mould cavity 8 than in other variants.

The basic mode of operation of the devices according to the inventionaccording to FIGS. 1a to 1 c, 2, 3, 4 a to 4 c and FIG. 12 and the basicsequence of the discontinuous method will now be described withreference to FIGS. 1a to 1c and FIGS. 4a to 4 c.

The mould is closed, the closing force is applied, and the carriage 6moved to its starting position. At the beginning of the injectionprocess, in FIG. 1a and FIG. 4a , the carriage 6, together with themould insert 7, is therefore in its starting position, in which thenozzle 2 is located at the front end, here the right end, of the mouldcavity 8 and therefore also at the front end of the runner 10. Now thesolidifiable plastic mass is injected via the nozzle 2 under highpressure and the carriage 6 is set in motion, wherein the front endportion of the mould cavity 8 is initially filled via the runner 10 andthe first connection 9. The solidifiable plastic mass, which penetratesslightly within the runner 10 below the leading part 3, forms a freemass front below the leading part 3, in FIGS. 1b and 4 b, which isessentially maintained during the movement of the carriage 6 in thedirection of the arrow P1. During the movement of the carriage 6, themould cavity 8 is successively filled with the solidifiable plastic massvia the connections 9. The runner 10 therefore ensures a successivefilling of the mould cavity 8 with solidifiable plastic mass and for acorresponding holding pressure phase. The thin-walled portions 10 a actas “flow brakes”, causing an increase in pressure, so that thesolidifiable plastic mass passes under suitable pressure in theconnections 9. In the case of thermoplastic masses, the trailing part 4supplied with coolant cools both the mass strands located in the runner10 and in the connections 9; in masses of elastomers or thermosettingplastics, the trailing part is heated in order to achieve chemicalcrosslinking of the plastic. As the carriage 6 advances, the runner 10emerges from the trailing part 4, which solidifies the mass strandsfound in the runner 10 and in the connections 9. As soon as the mouldcavity 8 is completely filled (FIG. 1 c, FIG. 4 c) or the individualcavities 8′ (FIG. 2) are filled with mass, the carriage 6 is stopped.Some force is still applied and then the supply of plastic mass is alsostopped. After a cooling phase, the mould is opened, and the mouldinsert 7 is opened by moving apart the jaws 7 a. The runner mass strand,together with the connecting strands, is now removed by separationbefore or after the ejection of the formed component or components.

FIG. 5, together with the sectional views in FIGS. 5a and 5b ,illustrates the mode of operation of an embossing device 14, which actslocally on the solidifiable plastic mass in the runner 10 in the regionof the connections 9. FIG. 5a is a section along the line Va-Va of FIG.5; FIG. 5b is a section along the line Vb-Vb of FIG. 5. For the sake ofclarity, the component 24 a to be formed from the plastic mass, therunner mass strand 25 a, and some connection mass strands 25 b areshown. The embossing device 14 has an embossing strip 14 a, which ispositioned stationary, for example on the mould insert 1. The embossingdevice 14 also comprises one of the number of embossing stamps 15,corresponding to the number of connections 9. The embossing stamps 15are positioned in a manner not shown in the carriage 6 so that, duringthe movement of the carriage 6 from the embossing strip 14 a, they canbe moved successively into their embossing position as soon as acavity—in the case of individual cavities—or a cavity portion is filledwith plastic mass. The mutual distance of the embossing stamps 15corresponds to the mutual distance of the connections 9. The sectionalview in FIG. 5a shows the position of an embossing stamp 15 in itsunactuated position in the case of a connection mass strand 25 b. FIG.5b shows the position of an embossing stamp 15 in its embossingposition, the embossing stamp 15 is retracted into the plastic mass inthe runner 10 and facilitates an increase in the pressure in the cavity8 after filling, in particular ensuring optimum filling ofthicker-walled regions of the cavity 8.

Components of a further variant of an embossing device 14′ and theirmode of operation are shown in FIGS. 6, 6 a and 6 b. FIG. 6a is asection along the line VIa-VIa of FIG. 6; FIG. 6b is a section along theline VIb-VIb of FIG. 6. The arrangement of the embossing strip, notshown here, is the same as the embodiment already described, namelystationary. The embossing stamps 15′ in this embodiment in particularare prepositioned within the mould insert 7 and one of the jaws 7 aformed by the mould insert 7, for example horizontally oriented. In theembodiment shown, for example, a component 24′ is produced which iscomposed of regular voluminous block-like elements 24′a. Each embossingstamp 15′ is assigned to the region of the mould cavity 8 which in eachcase forms one of the voluminous, block-like elements 24′a of thecomponent 24′. FIG. 6a shows the position of an embossing stamp 15′before embossing, FIG. 6b , during embossing. The embossing stamp 15′ ispressed into the mass in the voluminous, block-like element 24′a. Thevoluminous elements of the component have a larger volume shrinkage thanthe thin-walled, rod-shaped portions; since they cool more slowly, apressure supply of voluminous component elements on the thin-walled,rod-shaped portions would be very time-limited. The embossing stamps 15′ensure that the mass in the voluminous elements is locally morecompacted during cooling, so that the volume shrinkage iscorrespondingly reduced.

The variant of the invention shown in FIGS. 7 and 7 a is a variant forproducing one or more components in a continuous method. FIG. 7 and FIG.7a show an embodiment of the device according to the invention with amould with a rotary unit, wherein FIG. 7a shows a sectional view alongthe line VIIa-VIIa of FIG. 7. The rotary unit has a carrier 16displaceable in a continuous rotary motion by means of a drive unit, notshown, provided with a circular outer circumference, on the outercircumference of which a plurality of mould inserts 17 is arrangedimmediately adjacent to each other, so that all mould inserts 17 form amould insert circle. When all the mould inserts 17 are closed, thesupport 16 extends circumferentially around all of the mould inserts 17in a circular manner around a runner 10. At a part of the devicestationary relative to the rotary unit, for example a channel block ofthe mould, not shown, at the top of the support 16 and the rotary unit,a leading part 3′ and a trailing part 4′ are also positioned stationary.Analogous to the embodiments already described, a nozzle 2 leading awayfrom an injection unit 5 having the nozzle hole 2 a is preferablylocated between the leading part 3′ and the trailing part 4′. Theleading part 3′ and the trailing part 4′ have arcuately extending loweredge portions 3′a, 4′a, formed concentric with the runner 10, the edgesurfaces 3′b, 4′b of which, analogous to the embodiments alreadydescribed, form an enclosed leading and trailing zone in the closedmould together with the runner 10′. As shown in FIG. 7a , the mouldinserts 17 also comprise jaws 17 a, which, in this embodiment, aredesigned according to the circumference of the rotary unit in order to,when all mould inserts 17 are closed, together form the circularencircling, as a runner 10′ formed as a recess. The jaws 17 a of eachmould insert 17 contain, in the mutually braced position, at least oneseparate mould cavity 8′ and in each case at least one connection 9′formed as a channel, which opens into the recess formed between the jaws17 a and forming a portion of the runner 10′.

FIG. 7a shows the rotary unit in the region of the nozzle 2, wherein theexemplary V-shaped edge portion 3′a of the leading part 3 and the runner10′ formed between the two jaws 17 a can be seen.

To operate the device, the rotary unit is put into continuous andconstant rotational movement by the drive. Analogous to the embodimentsalready described, a free mass front forms during injection ofsolidifiable plastic mass in the leading zone below the leading part 3′in the runner 10′ while the individual cavities 8′ are filled insuccession via the runner 10′ and the connections 9′. The filledcavities 8′ are moved away from the nozzle 2 in the direction ofrotation (arrow P₂), wherein each mould insert 17 passes the trailingzone below the cooled (in the case of thermoplastics) or heated (in thecase of elastomers or thermosetting plastics) trailing part 4′ as thedistance from the casting site continues. The plastic mass in the runner10′, in the connections 9′ and in the respective cavity 8′ begins tocool. Finally, each mould insert 17 comes out of the trailing part 4′and the plastic mass cools down further and solidifies. In particular,after about a quarter to half of the circumference of the rotary unit,each mould insert 17 is automatically opened so that the mass strand inthe runner 10 can be separated together with the connection strands.This process also takes place continuously from mould insert 17 to mouldinsert 17. The mould inserts 17 are then automatically opened one afteranother, and the component formed in the cavity 8′ is automaticallyejected. FIG. 7 shows an exemplary immediately ejected component 24″.Subsequently, the mould inserts 17 are closed again automatically insequence and, during the continuous rotation of the rotary unit, passsuccessively back into the leading zone below the leading part 3′ andare again filled one after the other with plastic mass.

In an alternative variant, not separately shown, with a rotary unit ofall mould inserts, a continuous circular encircling mould cavity isformed, so that an “endless” profile, in particular a deformable,windable profile, with varying cross-sectional design, can be produced.

In a further alternative variant, not shown separately, for theproduction of one or more components in a continuous method in atransport, individual mould inserts are filled continuously, forexample, linearly, directly joined, as described, the components areremoved from the moulds, the mould inserts are closed again and fed backto the casting site.

If, after ejection of the components, the mould inserts are replaced bydifferently shaped mould cavities having mould inserts and thecomponents successively used again in these mould inserts, for exampleinjecting a second mass component can be carried out via a secondnozzle. Alternatively, a second rotary unit may be provided withcorresponding mould inserts.

Analogous to the embodiment according to FIGS. 4a to 4c , a steppedleading part 3′ can also be provided with a rotary unit in theembodiment.

The rotary unit is set in rotary motion in particular by an electricmotor with or without gears, which is controlled by the control of theinjection moulding machine or separately.

As the solidifiable plastic mass is continuously injected, filledcavities and manifold channel mass strands are moved away from thenozzle by the rotational movement of the rotary unit. These phases runspatially one after the other, but temporally simultaneously. Thisresults in a significant increase in productivity compared to aconventional injection moulding process.

FIGS. 8 to 11 show variants of a continuous supply of a rotary unit witha solidifiable plastic mass. All of these figures show nozzles 2′, 2″leading away from horizontally arranged injection units 5′, 5″ Thenozzles 2′, 2″ are positioned in a channel block 18, which is designedaccording to the arrangement and guiding of channels 19, 20, 21corresponding to several parts. From each nozzle 2′, 2″ a channel 19, 20leads into the centre of the respective channel block 18. Here, aconnection or a transition of these two channels 19, 20 is carried outin the channel 21, which opens into the nozzle 2 in the region of theleading and trailing part 3′, 4′.

In the embodiment shown in FIG. 8, portions of the channels 19, 20together with the channel 21 form a T-junction, at which a divertervalve 22 indicated in this figure ensures that the channel 21 isalternately supplied with melt from the injection unit 5′ and from theinjection unit 5″. The diverter valve 22 is correspondingly controlled,for example via pressure differences in the injection units 5′, 5″. Inthe embodiment shown in FIG. 9, a diverter valve 22′ is provided whichis coupled to a piston rod and a piston, so that the actuation of thediverter valve 22′ can be carried out hydraulically or pneumatically.Alternatively, the operation may be provided by means of an electricdrive. In this embodiment, the switching or release of the channels 19,20 is preferably ensured via a controller that takes into account thescrew stroke in the units 5′, 5″. In the variant shown in FIG. 10, themass flow to the channel 21 is regulated via needle valve nozzles 23. Inthis embodiment, the channel 21 can also be supplied with the mass fromboth channels 19, 20. This measure is particularly advantageous becausein this way the pressure can be kept constant when changing between theinjection units 5′, 5″. FIG. 11 shows an embodiment which corresponds infunction to that of FIG. 8, wherein here the two nozzles 2′, 2″ arearranged at right angles to each other, the two channels 19, 20 run inL-shapes to each other, and the channel 21 branches off from one ofthese L portions. With the diverter valve 22, a T-junction is thereforeformed again.

In the variants illustrated in FIGS. 8 to 11, the channel block 18 ispreferably a component of the mould and not a component of the injectionmoulding machine. However, it is also possible to provide the channelblock with a diverter unit as an independent assembly, which isconstructed in front of the mould on a fixed spanning sheet of theinjection moulding machine. This has the advantage that the samediverter unit of the channel block can be used for several moulds.

FIG. 12 shows, in an embodiment analogous to FIG. 1c , a variant of theinvention in which components of two different solidifiable plasticmasses can be produced in a two-component method. Two nozzles 2 areprovided, which are both positioned in the leading part 3. Otherwise,this embodiment corresponds to that shown in FIG. 1c . By means of thetwo nozzles 2, two differently composed plastic masses can thus beintroduced into the cavity 8 via the runner 10, wherein it is possiblefor the masses to be injected either simultaneously or alternately. Ifthe plastic mass is injected simultaneously, a component is created withan outer and an inner layer of different materials. If the nozzles arearranged next to each other, which is not shown here, a component can beformed which should have a longitudinal portion made of a hardermaterial and a longitudinal portion parallel thereto made of a softmaterial. If the plastic masses are injected successively, for example,a component with a different colour or rigidity of the material isproduced in individual longitudinal portions. For example, a hardercomponent is first injected at the start of a component, a soft,resilient component in the middle part, and then again a hard, stiffcomponent. The result is a component with high flexibility in the middleregion. By means of needle valve nozzles 23′, which are merely suggestedin FIG. 12, a targeted interruption of the mass flow can take place ineach case.

In a modification of the embodiment shown in FIG. 12, the two nozzlesare housed in a separate unit belonging to the injection mouldingmachine, in the mould, there is only one nozzle, which is suppliedalternately with the two different plastic masses.

FIG. 13, together with FIGS. 13a to 13c , shows a device 26 with sliders27 acting as flow brakes. The device 26 has a stationary actuating strip26 a with an actuating or control cam 26 b, which has a bevel 26 claterally next to the nozzle hole 2 a, offset slightly in the directionof the trailing zone. The position of the nozzle hole is indicated inFIG. 13a with a dashed line. The carriage 6 is equipped with sliders 27in the region of the runner 10. By means of a control device, thesesliders 27 are actuated as soon as the relevant portion of the runner 10has passed the nozzle 2 a in the direction of the trailing zone. As aresult, the flow cross-section in the runner 10 increases in thetrailing zone and enables better pressure transfer into the portions ofthe cavity 8 which are already filled with plastic mass. The slider 27therefore act as a flow brake in the runner 10. In FIG. 13a , thecomponent 24 a and the runner mass strand 25 a are shown veryschematically. FIG. 13b shows a slider 27 in its actuated position; FIG.13c shows a slider 27 in its unactuated position.

In all variants, the separation of the runner mass strands, togetherwith the connection mass strands and the ejection of the respectivecomponent, can already take place when the solidification process hasprogressed so far that these parts are dimensionally stable.

Suitable solidifiable plastic masses in the context of the methodaccording to the invention are all plastically processable materials,namely thermoplastics, thermosetting plastics, and elastomers. Dependingon the type of plastic mass, the nozzles are hot runner or cold runnernozzles.

In principle, it is possible to carry out the method in such a mannerand to design the device such that the mould cavity/ies are provided onstationary mould components and injected with at least one movinginjection unit via movable mould components.

LIST OF REFERENCE NUMERALS

-   1 . . . Mould insert-   2, 2′, 2″ . . . Nozzle-   2 a . . . Nozzle hole-   3, 3′ . . . Leading part-   4, 4′ . . . Trailing part-   3 a, 4 a, 3′a, 4′a . . . Edge portion-   3 b, 4 b, 3′b, 4′b . . . Edge surfaces-   5, 5′, 5″ . . . Injection unit-   6 . . . Carriage-   7 . . . Mould insert-   7 a . . . Jaws-   8, 8″ . . . Mould cavity-   9, 9′ . . . Connections-   10, 10′ . . . Runner-   10 a, 10 b . . . Section-   12 . . . Ejector-   13 . . . Heating element-   14, 14′ . . . Embossing device-   14 a . . . Embossing strip-   15, 15′ . . . Embossing stamp-   16 . . . Support-   17 . . . Mould insert-   17 a . . . Jaws-   18 . . . Channel block-   19, 20, 21 . . . Channels-   22, 22′ . . . Diverter valve-   23, 23′ . . . Needle valve nozzle-   24, 24′, 24″ . . . Component-   24′a . . . Block-like element-   24″ . . . Component-   25 a . . . Runner mass strand-   25 b . . . Connection mass strand-   26 . . . Flow brake device-   26 a . . . Actuating strip-   26 b . . . Control cam-   26 c . . . Bevel-   27 . . . Slider

1. A method for producing components or profiles from at least onesolidifiable plastic mass in an injection moulding facility, said methodcomprising stationary mould components and mould components which aremovable with respect thereto, wherein the movable mould componentscontain at least one mould cavity and the stationary mould componentshave at least one casting site, over which the solidifiable plastic massis injected into the area between the stationary mould components andthe mould cavity/ies in the movable mould components, while moving themovable mould components with the mould cavity/ies away from the castingsite, the method comprising: a) injection of solidifiable plastic massinto a runner formed in the movable mould components and, from there,via connections b1) either in portions into an individual mould cavityb2) or one after the other into individual mould cavities, c) whereinthe runner in the region of the casting site, as well as in a leadingzone located on the one side of the casting site in a direction counterto that of the movement of the moving mould components and in a trailingzone located on the other side of the casting site in the direction ofmovement of the moving mould components, is enclosed by at least onestationary, temperature-controlled mould component, d) wherein in therunner, a continuous runner mass strand is formed with attachment massstrands, which is transported away from the casting site with increasingcooling and solidification and increasing length, together with thefilled mould cavities and mould cavity portions, e) wherein the runnermass strand, together with the connection mass strands, after itssolidification and after opening the mould cavity or the mould cavitiesis separated from the component(s), and f) the component or thecomponents is/are ejected.
 2. The method according to claim 1, whereinit is a discontinuous method in which the movable mould components aremoved linearly.
 3. The method according to claim 1, wherein it is acontinuous method, in which movable mould components are continuouslyjoined together, are filled, the component(s) is/are removed from themould, and the mould components are recycled for refilling at thecasting site.
 4. The method according to claim 1, wherein it is acontinuous method in which the movable mould components are moved alonga closed circle.
 5. The method according to claim 1, wherein the mouldcomponent surrounded by the runner in the leading zone is heated orcooled.
 6. The method according to claim 1, wherein the mould componentsurrounded by the runner in the trailing zone is cooled or heated. 7.The method according to claim 1, wherein the solidifiable plastic massfills an elongate mould cavity in portions or individual, mould cavitiesrunning in a row via the connections, which are formed in at least onemould insert are formed, which is arranged on a linearly movablecarriage.
 8. The method according to claim 1, wherein after the fillingof the mould cavity or all mould cavities, the movable mould componentsare stopped, the supply of solidified plastic mass is stopped, and stepse) and f) follow.
 9. The method according to claim 1, wherein thesolidifiable plastic mass partially fills a circular circumferentialmould cavity in portions or individual mould cavities successivelyarranged in a circle via the connections, wherein the mould cavity orthe individual mould cavities is or are provided within mould insertswhich follow the circular outer circumference of a rotary unit followingthe circular shape directly following one another.
 10. The methodaccording to claim 1, wherein, in step e), the solidified runner massstrand and the solidified connection mass strands are continuouslyseparated after the emergence of the mould inserts from the trailingzone by means of successively opening the mould inserts.
 11. The methodaccording to claim 1, wherein, following step e), the mould inserts aresuccessively opened completely, either the component formed in therespective cavity is ejected or the component continuously formed in themould cavity extending in a circle is partially removed from the mould,wherein the mould inserts are then closed in sequence and, during thecontinuous rotation of the rotary unit, successively enter the leadingzone again.
 12. A device for producing components or profiles from atleast one solidifiable plastic mass in an injection moulding facility,said device comprising stationary mould components and mould componentswhich are movable with respect thereto containing at least one mouldcavity, wherein the stationary mould components have a heatable leadingpart and a coolable trailing part and have at least one casting site inthe region of the leading part and/or the trailing part, wherein: themovable mould components either comprise an elongate mould cavity orindividual cavities arranged in a row and have a runner designed as arecess, which is connected via connections either to the elongate mouldcavity or to the individual cavities, and the runner is enclosed by theleading part and the trailing part in the closed mould in the region ofthe leading part and the trailing part.
 13. The device according toclaim 12, wherein the movable mould components have a linearly movablecarriage which is provided with at least one mould insert which containsthe elongate mould cavity or the individual mould cavities, over theextent of which the runner is formed as a straight recess in the mouldinsert.
 14. The device according to claim 13, wherein the elongate mouldcavity extends substantially straight or overall curved arcuately. 15.The device according to claim 12, wherein the movable mould componentshave a rotary unit with a circular outer circumference, on which themould inserts immediately following the circular shape are arranged,which respectively contain either at least one mould cavity or togethercontain an individual mould cavity following a circular shape, whereinthe runner extends as a circular circumferential recess over all mouldinserts.
 16. The device according to claim 12, wherein the leading partand the trailing part comprise free edge portions with edge surfacesfacing the mould insert/mould inserts, which, when the mould is closed,tightly cover the runner.
 17. The device according to claim 12, whereinthe leading part is offset or placed lower relative to the trailing partso that the runner gap in the region below the leading part is thinnerwalled than in the region below the trailing part.
 18. The deviceaccording to claim 12, further comprising an embossing device withembossing stamps, which can be retracted locally in the runner in theregion of the connections or into the cavity/ies.
 19. (canceled)
 20. Thedevice according to claim 18, wherein the embossing device has anembossing strip which is arranged on a stationary mould component,wherein the embossing stamps are positioned in a movable mould componentin such a manner that, during the movement of this mould component, theycan be successively brought into their embossing position.
 21. Thedevice according to claim 12, further comprising a flow brake devicewith a stationary actuating strip arranged on a stationary mouldcomponent, and with sliders mounted in a movable mould component, whichare moved in the region of the leading part successively from the runneras soon as a portion of the runner has passed the nozzle in thedirection of the trailing part.
 22. The device according to claim 12,further comprising two injection units and a channel block (18) with twoof the injection units supplied with solidified plastic mass nozzles(2′, 2″), wherein from each nozzle, a channel extends into the centre ofthe respective channel block, wherein via a switching valve alternatelyone the two channels (19, 20) can be connected to a further channel (21)which extends to the casting site in the region of the leading andtrailing part (3′, 4′).
 23. The device according to claim 12, furthercomprising two injection units and a channel block with two of theinjection units supplied with solidified plastic mass nozzles, whereinfrom each nozzle a channel extends into the centre of the respectivechannel block, wherein via needle valve nozzles the two channels can beconnected simultaneously or alternately to a further channel whichextends to the casting site in the region of the leading and trailingpart.
 24. The device according to claim 12, wherein two nozzles areprovided, which are either both positioned in the leading part or arecomponents of a unit of the injection moulding machine.